THUM'S UP! : Wireless Troubleshooting of Intermittent Upsets

transcript

Steven Moore– Wireless Specialist

PresenterPresenter

Steven Moore

THUM'S UP! : Wireless Troubleshooting of Intermittent UpsetsTHUM'S UP! : Wireless Troubleshooting of Intermittent Upsets

Introduce the Process Identify the Process Impediment Investigate the Solution Options Implement a Solution Indicate the Business Results

The ProcessThe Process

Paper Producer Flows in a Waste Water area

– Remote Operation– EPA Spill Concerns– Process Critical Inventory

Instrumentation and Controls Overview– Multiple Control Systems– Process Enhancements– Old and New Instrumentation

Instrumentationand Wireless Network LayoutInstrumentationand Wireless Network Layout

Control Room & Shops

Instrumentationand Controls DiagramInstrumentationand Controls Diagram

Plant Network

DCS Network

PLC Network

Operator Station

Powerhouse

station with AMS

Device Manager

Emerson Smart

Wireless Gateway

The ProblemThe Problem

Conflicting Information– Operator saw unacceptable flow variability– Technician saw stable flow at the flow meter

Instrumentation Accessibility– Technician not typically stationed near flow meter– Tied to Remote PLC– Outdoors

Intermittent Behavior– Operator would see stable flow when technician present at

flow meter– No obvious process or environmental condition created

upset.

The CostsThe Costs

Risk of EPA Violation or Process Upset Operator Attention to Non-Profit Making Task Instrument Technician Trip to Field Disruption of Process during Diagnosis Harmony Among Employees

The OptionsThe Options Options Using Traditional Diagnostic Tools

– Station technician in area for faster response– Add local data acquisition– Replace transmitter and flow tube, and wiring…….

Options Changing the Process– Change I/O location to DCS– Change Pump/Pipe configuration– Additional Instrumentation

Options Using Wireless Technology with Improved Diagnostic Tools– Add THUM Wireless HART adapter for full HART connectivity– Activate Diagnostic option in Magnetic Flow transmitter– Monitor Diagnostics with Wireless Network’s On-Line AMS Device

Manager

The SolutionThe Solution Diagnostic Tools in the Field Device

– Activated Diagnostic Tools in Magnetic Flow Transmitter• Continuously Monitor Grounding Faults• Continuously Monitor Wiring Faults• Continuously Monitor for High Process Noise

Diagnostic Tools in the Shop– AMS Device Manager

• Alert Monitor• Audit Trail

Wireless Tools to Integrate All the Tools– THUM Wireless HART Adapter to Magnetic Flow Transmitter– Wireless HART Gateway– AMS Device Manager

Instrumentationand Controls DiagramInstrumentationand Controls Diagram

Plant Network

DCS Network

PLC Network

Operator Station

Powerhouse

station with AMS

Device Manager

Emerson Smart

Wireless Gateway

The CostsThe Costs

Diagnostic Upgrade to Magnetic Flow Transmitter THUM Wireless HART Adapter Installation Time and Materials Adding Device to Wireless Network Activate Monitoring in AMS Device Manager

The ResultsThe Results

Project Implementation– Time : Less than 2 hours– Cost : Less than $2000

Process Performance– No AMS Device Manger Alerts since implementation– No operator alerts since implementation

Profitability Impact– No operator distractions– No technician call outs– Confidence in operation

The SummaryThe Summary

The Problem and The Solution The Payback

The SummaryThe Summary

The Problem and The Solution The Payback

Where To Get More InformationWhere To Get More Information

Visit the Smart Wireless and Rosemount Flow Booths in the exhibit hall Featured demos:

• Emerson Smart Wireless solutions• Smart Wireless THUM Adapter• Wireless & Control

Attend any of the numerous wireless sessions Visit www.EmersonSmartWireless.com Visit www.hartcomm.org/

THUM'S UP! : Wireless Troubleshooting of Intermittent Upsets

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